Integrated tray and pallet system

ABSTRACT

The invention is directed to an integrated plastic tray and pallet system. The system includes a molded plastic pallet having an upper surface with tray components integrally formed with the remainder of the pallet extending upward from the upper surface. A plurality of pallet feet extend downward from a lower surface of the pallet. The pallet also includes side walls extending upward from the periphery of the upper surface. The system may include additional pallet and integrated tray structures without the pallet feet, and a top cap.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/077,048 filed Sep. 11, 2020, the contents of which are incorporated herein by reference and made a part hereof.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

N/A

FIELD OF THE INVENTION

The present invention is related to an integrated tray and pallet system which includes a pallet base having an upper surface with integrally formed trays extending upward from the upper surface and a bottom surface with downwardly extending feet.

DESCRIPTION OF THE PRIOR ART

Some pallet systems use trays to sort and organize products shipped on the pallet. Typically, these trays are designed to hold parts in well-defined locations, which makes them suitable for automatic loading and unloading.

Current common practice is to place a stack of trays onto a pallet and to—if needed—place a top cap on top of the stack. An example is Powertrain components for the North-American automotive industry, which are most often shipped in thermoformed trays that are placed onto a 48″×45″ “Powertrain” pallet. The pallet is necessary to allow the stacks to be moved with fork trucks and pallet jacks.

The use of a separate pallet at the bottom of a stack of trays has several potential negative aspects. For example, sometimes the available pallet footprints do not match the size of the trays or the size of the shipping vehicle. This results in sub-optimized freight efficiencies. For instance, currently established pallet sizes (1200×800 mm; 1200×1000 mm; 40×48″; 48×45″) do not efficiently fill out the footprint of sea containers. To do this, a pallet size of, for example, approximately 1185×985 mm would be much more efficient.

Additionally, having trays sitting on a pallet adds a potential for trays to move a bit on the pallet. This makes it more difficult for automation to locate parts for unloading.

The present invention provides a tray integrally formed with pallet features that overcome some or all of the issues with prior systems.

SUMMARY OF THE INVENTION

The present invention is directed to an integrated tray and pallet system. The system overcomes the issues with the prior systems by integrating the functional elements of the pallet (e.g., feet, runners, fork straps) into the tray that is placed at the bottom of a stack. That is, the trays are integrally formed with the pallet features. Pallets and integrated trays without feet, etc. can be used to stack on the pallet and tray system having feet. A top cap can be placed on the topmost pallet and tray. Both trays with and without pallet elements can be produced in the same tool (i.e., mold) with typically a plastic injection molding process. This tool has either inserts or two separate mold halves to produce these two versions.

In accordance with one aspect of the invention an integrated tray and pallet system is provided. The tray and pallet system comprises a first generally rectangular pallet base having a planar upper surface and a plurality of integrally formed trays having tray walls extending upward from the upper surface of the first pallet base. The first pallet base can have a plurality of feet extending downward from a bottom surface of the first pallet base.

The pallet base can further include a first side wall extending upward from an edge of a first side of the first pallet base, a second side wall extending upward from an edge of a second side of the first pallet base, a third side wall extending upward from an edge of a third side of the first pallet base and a fourth side wall extending upward from an edge of a fourth side of the first pallet base. Along with the integrally formed tray walls, the first, second, third and fourth side walls can form a part of each tray.

Each of the first, second, third and fourth side walls can include a plurality of outwardly extending ribs. The pallet base, trays, feet and side walls can all be formed from a molded plastic.

Each of the plurality of integrally formed trays can be rectangular and can form an array of columns and rows (e.g., such as an array of five by two). Alternatively, the trays can be other shapes and positions on the pallet.

The system can further include a second generally rectangular pallet base having a planar upper surface and a plurality of integrally formed trays having tray walls extending upward from the upper surface of the second pallet base. The second pallet base can be configured to stack on the first pallet base. Additional pallet bases can also be stacked on the first and second pallet bases.

The system can also include a top cap configured to be placed on top of the second pallet base. Alternatively, the top cap can be used on the topmost one of a stack that has a greater number of pallet bases than the first and second pallet bases.

In accordance with another aspect of the present invention, an integrated tray and pallet system comprises a first plastic rectangular pallet base having an upper planar support surface and a first tray integrally formed with the first pallet base having tray walls extending upward from the support surface. The system can further comprise a second tray integrally formed with the first pallet base having tray walls extending upward from the support surface. In fact, the system can comprise a plurality of additional trays integrally formed with the first pallet base having tray walls extending upward from the support surface.

The first tray and the additional plurality of trays can form an array of trays on the first pallet base. Moreover, each of the first tray and the additional plurality of trays can be rectangular. However, the trays can be other shapes, sizes and positions on the pallet base as desired for a particular use.

The pallet base can include a plurality of plastic feet extending downward from a bottom surface of the first rectangular plastic pallet base. Additionally, the pallet base can include a first plastic side wall extending upward from an edge of a first side of the first rectangular plastic pallet base, a second plastic side wall extending upward from an edge of a second side of the first rectangular plastic pallet base, a third plastic side wall extending upward from an edge of a third side of the first rectangular plastic pallet base and a fourth plastic side wall extending upward from an edge of a fourth side of the first rectangular plastic pallet base.

Each tray can include a tray wall formed from one of the first plastic side wall, the second plastic side wall, the third plastic side wall and the fourth plastic side wall. Additionally, each tray can include a tray wall having a first end segment, a middle segment and a second end segment wherein a height of the middle segment is less than a height of the first end segment and a height of the second end segment.

Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of an integrated tray and pallet system in accordance with the present invention;

FIG. 2 is a bottom perspective view of the tray and pallet system of FIG. 1;

FIG. 3 is a bottom perspective view of a tray without pallet feet;

FIG. 4 is a perspective view of a complete stack of a tray with pallet feet, four trays without pallet feet and a top cap in accordance with an aspect of the present invention;

FIG. 5 is a perspective view of a plurality of complete stacks of FIG. 4;

FIG. 6 is a cross-sectional view of a mold for forming a tray with feet and without feet;

FIG. 7 is a top perspective exploded view of an integrated tray and pallet system having a base pallet with legs and a stacking pallet without legs;

FIG. 8 is a bottom perspective exploded view of the integrated tray and pallet system having a base pallet with legs and a stacking pallet without legs of FIG. 7;

FIG. 9 is a side view of an integrated tray and pallet; and,

FIG. 10 is a perspective view of the integrated tray and pallet of FIG. 9.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

The present invention overcomes many of the issues of having a pallet with a separate tray or plurality of trays by integrating the tray (or trays) directly into the pallet. That is, the trays are integrally formed with the rest of the pallet in the same mold.

An integrated tray and pallet system 10 is shown in FIGS. 1-2. The system can be viewed as a pallet 12 having integrally formed trays 14 extending upward from an upper surface 16 of the pallet 12. The upper surface 16 has a generally rectangular shape. The pallet 12 also includes a plurality of feet 18 extending downwardly from a lower surface 20 of the pallet 12.

The pallet 12 has a first side wall 22, a second side wall 24, a third side wall 26 and a fourth side wall 28 extending upward about a perimeter of the upper surface 16. The trays 14 are defined by upwardly extending interior walls 30 combined with a portion of one or more of the pallet side walls 22, 24, 26 and 28, and the upper surface 16.

While the pallet is shown having three rows of three feet 18 each, it can have more or fewer depending on the size of the pallet desired. Additionally, the pallet 12 can be provided with additional pallet features, such as runners connecting the feet, internal reinforcement, etc. As partially shown in FIG. 1, the side walls 22, 24, 26 and 28 include outwardly extending ribs forming rectangular openings. Similarly, the upper or lower surfaces can include ribs and/or openings.

The pallet system 10 of FIG. 1 also shows one of the trays 14 loaded with a product 32. Different products can be placed in each of the trays 14.

In the embodiment of FIG. 1, ten trays 14 are shown in a five by two array. However, more or fewer trays 14 can be formed in various sizes, shapes and positions on the upper surface as desired for a particular purpose.

The internal walls 30 can be formed to have various features. In the example of FIG. 1, each wall 30 includes a first end portion 34, a second end portion 36 and a middle portion 38. The middle portion 38 has a height that is lower than a height of the first and second portions 34, 36. Collectively, four end portions from four trays 14 form columns in the interior of the pallet 12 as illustrated in FIG. 1.

The system can also include the combination pallet with integral tray without all of the pallet features. For example, referring to FIG. 3, a pallet 40 is shown without feet. Instead, the pallet 40 includes a smooth lower surface 42. The opposing upper surface can be formed to include the integral trays identical to the pallet 12 and trays 14 of FIG. 1. The pallet 40 includes perimeter lip or skirt 45 that enables the pallet 40 to securely stack onto another pallet 12 with feet, or another pallet 40 without feet.

A stack 44 of pallets with a top cap 46 (which can also be part of the system) is shown in FIG. 4. The top cap 46 includes structures 48 for accepting the feet 18 of a pallet 12 having feet. Accordingly, multiple such stacks 44 can be placed on top of each other as shown in FIG. 5.

The entire system is preferably formed from an injection molded plastic. FIG. 6 illustrates an injection mold 50 for forming either the pallet 12 having feet or the pallet 40 without feet but having a perimeter lip for stacking on other pallets. The mold 50 includes a stationary mold half 52 and two moving mold halves. The moving mold halves include a first moving mold half 54 for forming feet 18, and a second moving mold half 46 for forming the lip or skirt 45. Accordingly, the upper features of each pallet 12 and 40 are identical.

While the system is preferably plastic, other materials (e.g., metal reinforcements) can be used as necessary.

FIGS. 7-8 show an exploded view of an integrated tray and pallet 60 having feet 18 and an integrated tray and pallet 62 without feet that can be stacked on the pallet 60 with feet. FIGS. 9-10 show views of just the tray and pallet 60. Both pallets 60, 62 are similar to those shown in FIGS. 1-5, however, the middle portion 38 of each wall 30 is less pronounced (i.e., high).

As also evident in the pallet 10 of FIG. 1, the side walls 22, 24, 26 and 28 of the tray and pallet 60 have an upper portion 64 that is inset from the rest of the side wall. This forms a ledge 66 around the periphery of the side walls that will support the skirt 45 of a pallet 62 without legs that is stacked on top of it. Additionally, the horizontal top wall 68 of the upper portion 64 will contact the edge of the bottom surface 45 of the pallet 62.

Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood within the scope of the appended claims the invention may be protected otherwise than as specifically described. 

I claim:
 1. An integrated tray and pallet system comprising: a first generally rectangular pallet base having a planar upper surface; and, a plurality of integrally formed trays having tray walls extending upward from the upper surface of the first pallet base.
 2. The integrated tray and pallet system of claim 1 further comprising a plurality of feet extending downward from a bottom surface of the first pallet base.
 3. The integrated tray and pallet system of claim 2 further comprising: a first side wall extending upward from an edge of a first side of the first pallet base; a second side wall extending upward from an edge of a second side of the first pallet base; a third side wall extending upward from an edge of a third side of the first pallet base; and, a fourth side wall extending upward from an edge of a fourth side of the first pallet base.
 4. The integrated tray and pallet system of claim 3 wherein each of the plurality of integrally formed trays is rectangular.
 5. The integrated tray and pallet system of claim 4 wherein the plurality of integrally formed trays form an array of columns and rows.
 6. The integrated tray and pallet system of claim 5 wherein the array is five by two.
 7. The integrated tray and pallet system of claim 3 wherein each of the first, second, third and fourth side walls include a plurality of outwardly extending ribs.
 8. The integrated tray and pallet system of claim 1 wherein the first pallet base and the plurality of integrated trays are formed from a molded plastic.
 9. The integrated tray and pallet system of claim 1 further comprising: a second generally rectangular pallet base having a planar upper surface; and, a plurality of integrally formed trays having tray walls extending upward from the upper surface of the second pallet base, the second pallet base configured to stack on the first pallet base.
 10. The integrated tray and pallet system of claim 9 further comprising a top cap configured to be placed on top of the second pallet base.
 11. The integrated tray and pallet system of claim 3 wherein the first side wall, the second side wall, the third side wall and the fourth side wall form portions of the tray wall for respective ones of the plurality of integral trays.
 12. An integrated tray and pallet system comprising: a first plastic rectangular pallet base having an upper planar support surface; and, a first tray integrally formed with first pallet base having tray walls extending upward from the support surface.
 13. The integrated tray and pallet system of claim 12 further comprising a second tray integrally formed with the first pallet base having tray walls extending upward from the support surface.
 14. The integrated tray and pallet system of claim 12 further comprising a plurality of additional trays integrally formed with the first pallet base having tray walls extending upward from the support surface.
 15. The integrated tray and pallet system of claim 14 wherein the first tray and the additional plurality of trays form an array of trays on the first pallet base.
 16. The integrated tray and pallet system of claim 15 wherein each of the first tray and the additional plurality of trays is rectangular.
 17. The integrated tray and pallet system of claim 14 having a plurality of plastic feet extending downward from a bottom surface of the first rectangular plastic pallet base.
 18. The integrated tray and pallet system of claim 17 further comprising: a first plastic side wall extending upward from an edge of a first side of the first rectangular plastic pallet base; a second plastic side wall extending upward from an edge of a second side of the first rectangular plastic pallet base; a third plastic side wall extending upward from an edge of a third side of the first rectangular plastic pallet base; and, a fourth plastic side wall extending upward from an edge of a fourth side of the first rectangular plastic pallet base.
 19. The integrated tray and pallet system of claim 18 wherein each tray includes a tray wall formed from one of the first plastic side wall, the second plastic side wall, the third plastic side wall and the fourth plastic side wall.
 20. The integrated tray and pallet system of claim 19 wherein each tray includes a tray wall having a first end segment, a middle segment and a second end segment wherein a height of the middle segment is less than a height of the first end segment and a height of the second end segment. 